Restoring the Art Deco Metalwork at Philadelphia’s U.S. Custom House
My team at Metal Man Restoration was hired to restore the metalwork at the U.S. Custom House in Philadelphia, a historic federal building known for its Art Deco design. The scope covered 400 steel casement windows plus all exterior aluminum and stainless steel doors, transoms, and light fixtures. The project ran two and a half years, completed hand-in-hand with Painters Union Local 21.
The short version
- The project: the exterior metalwork of the U.S. Custom House in Philadelphia, a historic Art Deco federal building.
- Scope: 400 steel casement windows, plus all exterior aluminum and stainless steel doors, transoms, and light fixtures.
- Two and a half years of work, completed hand-in-hand with Painters Union Local 21.
- Condition: the steel frames showed extensive paint wear and rust scale, and the aluminum and stainless had gone more than 40 years without cleaning.
- We repaired, primed, and repainted the windows, and cleaned and preserved every aluminum and stainless surface to halt oxidation and corrosion.
- The result protected the building’s Art Deco metalwork and returned the exterior to a finish worthy of a national landmark.
Some restorations are measured in pieces, others in years. The Philadelphia Custom House was both. A federal Art Deco landmark with hundreds of windows and a full exterior of aluminum and stainless steel demands a plan, a crew, and the patience to do every surface correctly. This is what that kind of project looks like.
What We Restored
The work covered the building’s 400 steel casement windows along with all of its exterior aluminum and stainless steel: the doors, transoms, and light fixtures that define an Art Deco facade. The scale is what makes a job like this rare. Restoring it meant working methodically across the entire building rather than treating any one element in isolation.
The Condition: Decades of Exposure
Years of weather had taken a toll. The steel window frames showed extensive paint wear and rust scale, the kind of damage that spreads if it is left alone. The aluminum and stainless steel elements were structurally fine but had gone more than 40 years without a proper cleaning, and that neglect dulls the metal and invites corrosion over time.
How We Restored the Metalwork
Our craftsmen worked methodically across the building. For the steel windows, that meant repairing the frames, priming them, and repainting, so the rust scale was halted and the metal was protected again. We treated the windows as the long-term assets they are, not as surfaces to paint over.
For the aluminum and stainless steel, the job was proper cleaning and preservation of every surface to halt oxidation and corrosion. Done correctly, that protects the metal for decades. The full effort ran two and a half years, carried out hand-in-hand with Painters Union Local 21, and returned the exterior to a finish worthy of a national landmark.
Why Large Projects Need a Methodical Plan
On a building with 400 windows and a full exterior of aluminum and stainless, the difference between success and a mess is sequencing. Each surface needs the right treatment, the work has to move logically around the building, and the trades have to coordinate. Partnering with Painters Union Local 21 kept a project of this size moving without sacrificing the care each element required.
What This Means for Owners of Large Historic Buildings
If you steward a large historic building, the Philadelphia Custom House shows that scale is not a reason to replace original metal. Hundreds of steel windows and a full Art Deco exterior were repaired and preserved rather than torn out, which protects the building’s character and its budget. The key is a phased plan and the right treatment for each metal. For the broader approach, see our architectural metal maintenance guide for property managers.
Common Questions About Large-Scale Architectural Metal Restoration
These are the questions facilities teams and owners of large buildings ask us most before a big metal restoration.
Can hundreds of steel windows be restored rather than replaced?
Yes. At the Philadelphia Custom House we repaired, primed, and repainted all 400 steel casement windows. Restoring original steel windows preserves the building’s design and is often more cost-effective than replacing them with modern units that do not match.
How do you clean aluminum and stainless steel on a historic facade?
With methods matched to each metal, then a preservation step that halts oxidation and corrosion. The Custom House aluminum and stainless had gone over 40 years without cleaning. Proper cleaning restored the metal and protected it, rather than just making it look better for a season.
How long does a large metal restoration take?
It depends on scope. The Philadelphia Custom House ran two and a half years because of the number of windows and the full exterior of aluminum and stainless steel. A realistic timeline comes out of a survey of the building and the condition of each metal element.
Do you work with other trades and unions?
Yes. The Philadelphia project was completed hand-in-hand with Painters Union Local 21. On large landmark jobs, coordinating with other trades and union crews is part of the work, and it keeps a multi-year project organized and on track.
How do I start a large restoration project?
Start with a conversation and a survey. Send us the building location and photos of the metal elements, and we will assess scope, condition, and a phased plan. We will tell you honestly what can be restored and what the work would involve. You can reach us through our contact page.
Stewarding a large historic building with metal that needs care?
We restore steel windows, architectural aluminum and stainless steel, and ornamental metal at any scale for government, institutional, and commercial buildings across the New York metro and the tri-state area. Call or text (914) 662-4218, or tell us about your project.